BP G5M-R clutch cabling! A new alternate solution!

[Christ]

The Honda one I replaced had the link type that slides into the notch at the top of the pedal. Rockauto has a couple pics. (for 88 accord, $28 from Dorman)

I'm actually gona dbl check what o said today... O may have been thinking of adiff car, cuz I think my 89 and 91 also had the upper draw link.

[Afro]

This is some great research everyone. Those Honda ones look pretty good. The only problem I see is with the flat end. When I built my front transmission mount for the G5M-R it comes really close to the clutch lever, so with all that stuff from the Honda cable slotted behind the lever, it would probably run into my mount. I guess a mount re-design is always possible though!And I guess you'd just wrap the cable around the transmission once before connecting it?
Post some pics if anyone uses the Honda ones!

[Christ]

The Honda cable gets routed over/in front of the valve cover across the engine then down to the trans at a slight angle. All in all, it's about 5 feet long IIRC. You could route it under the trans to take up the slack without having tight angles in it.

[Rocketman]

Too tight of an angle and the cable will chew through its housing, so I wouldn't go wrapping it around the transmission. You could always find a way to trim the sheath/cable to fit

[Afro]

Too tight of an angle and the cable will chew through its housing, so I wouldn't go wrapping it around the transmission. You could always find a way to trim the sheath/cable to fit

I was more just joking about the wrapping it around the transmission but that's a very good point and one I didn't think about. I have a somewhat tight angle in mine now that I might have to correct... Thanks for the tip!

[Rocketman]

That's why I had to replace the cable on the Honda to begin with - the cable was lodged at an angle & it chewed right through the sheath over time! made it impossible to use the clutch

[Afro]

I figure the metal housing of the Volvo's cable will extend that life by a fair bit though if it's at a slightly tight angle? The BP we bought from Sask just chewed through the throttle cable because of that today, so I totally realize how this can happen. Never seen it before, so good lesson!

[Afro]

Here's a picture of the underside Rocketman, as promised. The bent metal provides ample support and is welded along 3 seams.

[Christ]

I think the concern was that the bend will flex toward the arm when your oress the clutch pedal.

[Afro]

One suggestion - gusset your cable bracket where the adjuster sits. The 90° plate supported only by the weld will be prone to cracking, it's under a lot of stress. Looks great though, very nice work!

In other words he thought that the piece of metal with the hole in it was unsupported other than by a weld, which makes sense because there was no picture of the thicker metal supporting it. In that case I would also be worried that the weld would crack or bend, but with the thicker metal below it it doesn't deflect at all under testing.

That's my take on what Rocketman said.

[Christ]

In that case, let me state my concern that the bend will flex toward the arm under the pressure of the cable pulling the lever up.

I only say this because there's nothing there to transfer the load to the main shaft of the bracket.

If it does fail, it'll probably be a long time from now, so it's not much of a concern, it's more of an "on paper" observation for me. Just wanted to get it out there, I guess.

To clarify, I think over time, the 90 degree bend is going to turn into more like a 120 degree bend from the pressure of the cable repeatedly being applied.